System and method for forming a molded component with an insert

Abstract

A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

1 . A molded article comprising:
 an insert including a projection extending from a base, the projection defining a receptacle having a first engagement feature disposed on an inner surface thereof;   a plug including a first material disposed within the receptacle of the projection and including a second engagement feature matingly receiving the first engagement feature to retain the plug within the receptacle, the plug including an alignment feature operable to receive an external structure to align the insert with the external structure; and   a second material surrounding the projection and the base and being spaced apart and separated from the plug.   
     
     
         2 . The molded article of  claim 1 , wherein the external structure is fixture of a mold. 
     
     
         3 . The molded article of  claim 2 , wherein the fixture extends from a surface within a cavity of the mold, the fixture received by the alignment feature to position the insert relative to the surface of the mold when the second material is applied to the insert. 
     
     
         4 . The molded article of  claim 3 , wherein the alignment feature is a cylindrical bore formed through the plug and the fixture is a cylindrical post, the cylindrical post being received by the cylindrical bore to align the insert relative to the surface of the mold when the second material is applied to the insert. 
     
     
         5 . The molded article of  claim 4 , wherein the cylindrical bore is elongate and extends through a first end of the plug and a second end of the plug. 
     
     
         6 . The molded article of  claim 1 , wherein the first engagement feature includes a first series of threads, the first material of the plug engaging the first series of threads to define the second engagement feature. 
     
     
         7 . The molded article of  claim 1 , wherein the first material is an elastomer. 
     
     
         8 . The molded article of  claim 1 , wherein the base extends laterally outwardly from the projection. 
     
     
         9 . A sole structure incorporating the molded article of  claim 1 . 
     
     
         10 . An article of footwear incorporating the molded article of  claim 1 . 
     
     
         11 . A molded article comprising:
 an insert including a projection extending from a base, the projection and the base being embedded in a first material; and   a plug including a second material disposed within a receptacle of the projection and being spaced apart and separated from the first material by a wall of the projection, the plug including an alignment feature operable to receive an external structure to align the insert with the external structure.   
     
     
         12 . The molded article of  claim 11 , wherein the external structure is fixture of a mold. 
     
     
         13 . The molded article of  claim 12 , wherein the fixture extends from a surface within a cavity of the mold, the fixture received by the alignment feature to position the insert relative to the surface of the mold when the second material is applied to the insert. 
     
     
         14 . The molded article of  claim 13 , wherein the alignment feature is a cylindrical bore formed through the plug and the fixture is a cylindrical post, the cylindrical post being received by the cylindrical bore to align the insert relative to the surface of the mold when the second material is applied to the insert. 
     
     
         15 . The molded article of  claim 14 , wherein the cylindrical bore is elongate and extends through a first end of the plug and a second end of the plug. 
     
     
         16 . The molded article of  claim 11 , wherein the insert includes a first series of threads to define a first engagement feature, the second material of the plug engaging the first series of threads to define a second engagement feature that retains the plug within the insert. 
     
     
         17 . The molded article of  claim 11 , wherein the second material is an elastomer. 
     
     
         18 . The molded article of  claim 11 , wherein the base extends laterally outwardly from the projection. 
     
     
         19 . A sole structure incorporating the molded article of  claim 11 . 
     
     
         20 . An article of footwear incorporating the molded article of  claim 11 .